Original MINI Wheels are cast from molten aluminium. The liquid metal is filled into a mold where it cools before it is removed, strictly monitored by the latest computer technology which guarantees the high quality of our wheels. This casting process reduces costs and allows a high degree of precision and freedom of design. Cast wheels are low in weight and high in stiffness.

In the forging process, the wheel is forged from the solid piece of aluminum. The high-end option is to mill the entire spoke design after forging the base material. Forged aluminium wheels are 10 to 20 % lighter in weight than aluminium cast wheels and allow a more delicate design of the spokes.

Cylindrical flow forming is a pressure forming process. While spinning, pressure is applied to the inner barrel of the cast wheel. This process stretches and compresses the aluminum, which increases tensile strength and makes it possible to achieve particularly low wall thicknesses for the rim. The result is a very light-weight and strong wheel with significant benefits In terms of shock resistance, elongation and load capacity.

This method can also be used for both forged and cast wheels. Here, non-structurally relevant mass on the wheel is reduced by machining of material from the spokes. This further reduces the wheel weight and creates premium styling effects as undercutting between the spoke connection and the well base gives the rim styling a three-dimensional appearance.

Regardless of which manufacturing technologies are used, the surfaces of Original MINI Light Alloy Wheels can be finished in a variety of ways. The basic method – powder coating – makes the wheel resistant to environmental factors such as corrosive de-icing salt. In the past, light alloy wheels were often painted silver with a clear lacquer coating. Today, the BMW portfolio includes numerous designs and refinements that require an elaborate finishing process.